Systems and methods for monitoring, inferring state of health, and optimizing efficiency of refrigeration systems

ABSTRACT

Systems and method for operating and monitoring refrigerators are described. Temperature cycles within the compartment are characterized using statistical, frequency and pattern analysis techniques to derive a steady-state characteristic of temperature within the compartment. A thermal sensor inside the conditioned area is monitored and temperature data sets can be analyzed to determine performance in comparison to a baseline, and energy consumption. Analysis of continuous temperature readings taken from individual or groups of freezers identifies patterns of variations in temperature cycles from which feedback on efficiency can be inferred. Electrical load can be determined by measuring or estimating current usage and identifying periods of time when compressors are active in the refrigerator.

PRIORITY CLAIM

The present application is a continuation of U.S. patent applicationSer. No. 14/275,771, filed May 12, 2014, which was scheduled forissuance as U.S. Pat. No. 10,337,964 on Jul. 2, 2019, and which is acontinuation of U.S. patent application Ser. No. 13/048,698, filed Mar.15, 2011, which issued as U.S. Pat. No. 8,725,455 on May 13, 2014 andwhich claimed priority from U.S. Provisional Patent Application No.61/314,014 filed Mar. 15, 2010, which applications are expresslyincorporated by reference herein for all purposes.

TECHNICAL FIELD

The present invention relates generally to refrigeration systems andmore particularly to systems and methods for monitoring the status,condition, performance and energy consumption.

BACKGROUND

Poor maintenance, misconfiguration or improper installation can resultin wasted energy, decreased reliability and increased operational costsof refrigeration systems. Current maintenance practices entail frequentand costly inspections by trained technicians, or in rare instances, theinstallation of costly instrumentation to directly monitor themechanical compressors and related components of the refrigerationsystem. Refrigeration equipment used in biomedical research, forexample, typically goes through preventive maintenance inspections onceevery six months. Trained technicians perform manual inspectionsgathering performance data from each freezer to determine whether therefrigeration system requires additional maintenance. These inspectionsare labor intensive, costly and inefficient because the entirepopulation of refrigeration systems must be inspected even though only asmall percentage might require repair or maintenance.

One type of refrigeration system, Ultra Low Temperature (ULT) Freezerscapable of maintaining storage temperatures of −80° C., are usedextensively by research organizations and Life Science companies tostore research specimens. The unexpected failure of a ULT Freezer or anyrefrigerated storage system in a life science application can result inthe catastrophic loss of high-value, mission critical researchspecimens. To avoid loss, companies often adopt a policy calling forreplacement of refrigeration systems after five years of service forlack of an affordable option to detect the onset of problems or failure.

Over time, all equipment suffers a loss of operating efficiency due tomechanical degradation, deferred maintenance or simple misconfiguration.According to US Government data, Life Science research and manufacturingfacilities consume 2× to 8× more energy than commercial office buildingsand “plug loads”, energy consumed by equipment plugged into walls,consumes an estimated 20% to 45% of total energy used. For lack of anaffordable and easy to deploy monitoring solution, these assets are“hidden” sources of wasted energy—energy that is 100% recoverable ifaffordable tools existed to manage them.

SUMMARY

Certain embodiments of the present invention comprise systems andmethods for measuring and determining the status, health, performance,operating efficiency and energy consumption of the mechanical andelectronic control systems of a refrigerator system by analyzingindirect indicators of status or performance, such as temperature in thestorage compartment and other parameters. The refrigeration systems aremonitored by wireless sensors which transmit data to an applicationserver for evaluation. Data may be processed and plotted against time toform performance profiles for each freezer that can be represented witha mathematical function, such as a sine wave. The application server maybe accessed through any web browser, and the user can have a distinctlogin identification and password. In certain embodiments, systems andmethods are provided that assess efficiency and reliability issuesassociated with preventive maintenance, predicting when and what typesof maintenance will need to be performed. The application can group andrank freezers according to their operating efficiency based on analysisand inferences drawn from their temperature profiles. The informationmay then be used to identify lower ranked freezers that requireimmediate or extensive service, based on measurements from sensors thathave known correlations, and maintenance can be conveniently scheduledfor lower ranked systems before they fail, while maintenance on higherranked freezers can deferred with low risk and significant cost savings.

Other embodiments include methods for determining or inferring theelectrical load drawn by an individual asset, such as a freezer, andtracking the location of one or multiple assets. In one embodiment, asingle current reading for the entire circuit of multiple freezers canbe taken periodically. Algorithms of the patterned behavior of multiplefreezers can be formulated to the amount of current drawn through eachunit that is connected in parallel. Patterned behavior can indicatewhich freezer is drawing an increased amount of current and becomingless efficient. In another embodiment, tracking the location ofindividual assets may be accomplished by magnetometer readings beingtransmitted to and processed by the application server. The user canview and manipulate a 3D map of one or multiple freezers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a refrigeration unit subject to monitoring by theinvention.

FIG. 2 illustrates possible options for the flow of data.

FIG. 3 temperature profiles for refrigeration units.

FIG. 4 illustrates the condenser cycle within a temperature profile.

FIG. 5 illustrates the tracking embodiment of the invention.

FIG. 6 is a simplified block schematic illustrating a processing systememployed in certain embodiments of the invention.

DETAILED DESCRIPTION

Embodiments of the present invention will now be described in detailwith reference to the drawings, which are provided as illustrativeexamples so as to enable those skilled in the art to practice theinvention. Notably, the figures and examples below are not meant tolimit the scope of the present invention to a single embodiment, butother embodiments are possible by way of interchange of some or all ofthe described or illustrated elements. Wherever convenient, the samereference numbers will be used throughout the drawings to refer to sameor like parts. Where certain elements of these embodiments can bepartially or fully implemented using known components, only thoseportions of such known components that are necessary for anunderstanding of the present invention will be described, and detaileddescriptions of other portions of such known components will be omittedso as not to obscure the invention. In the present specification, anembodiment showing a singular component should not be consideredlimiting; rather, the invention is intended to encompass otherembodiments including a plurality of the same component, and vice-versa,unless explicitly stated otherwise herein. Moreover, applicants do notintend for any term in the specification or claims to be ascribed anuncommon or special meaning unless explicitly set forth as such.Further, the present invention encompasses present and future knownequivalents to the components referred to herein by way of illustration.

Certain embodiments of the present invention provide systems and methodsfor operating and monitoring refrigerators, including ULT freezers.Certain of the techniques described herein employ low cost, minimallyinvasive monitoring equipment that can identify operationalcharacteristics of the monitored equipment and produces a range ofperformance measurements. Some of the performance measurements may beobtained indirectly. In one example, certain operational characteristicsof commercial refrigeration systems may be determined by monitoringtemperature cycles within a refrigerated compartment. Temperature cyclescan be correlated to functional efficiency of compressors and othercomponents.

For the purposes of this description, the state of health of arefrigeration system can be taken to include operational efficiency ofthermodynamic cycles used for heat pumps and refrigerators. The state ofhealth of the system may be used to diagnose specific causes ofperformance issues such as loss of a circulating refrigerant such asFreon, poor seals, inefficient or malfunctioning compressors, valves andother components. A current state of health may be assessed by comparingtemperature cycles with plural baseline characteristics obtained from abroad sample of similar refrigeration systems.

FIG. 1 is a simplified representation of a freezer 100 that is monitoredaccording to certain aspects of the invention. The freezer 100 has aninternal compartment, shown generally at 108 that is maintained at adesired temperature by a refrigeration device 106. For example,refrigeration device 106 may operate using a thermodynamic refrigerationcycle such as the Carnot cycle and may comprise one or more compressors,condensers, evaporators 106. Refrigeration device 106 may employ acharge of a refrigerant, such as Freon. It will be appreciated that athermodynamic refrigeration cycle can serve as a refrigerator and/or asa heat pump. Accordingly, certain aspects of the present invention maybe applied to heating and cooling systems. However, for the purpose offacilitating the appreciation of the presently disclosed inventions, arefrigeration device 106 will be assumed to operate using Freon in orderto achieve deep cooling of a compartment 108 used to store items andmaterials which may include, for example, biological samples. It will beappreciated that the invention may be used in commercial food storagesystems, consumer equipment and any other refrigeration system or systemthat uses a heat pump. In one example, an optimal and/or desiredpractical operating temperature for a ULT freezer is approximately −80°Celsius. The selection of operating temperature is typically made basedon application requirements and operational limits of the refrigerant orother component of system 100. In the example of a ULT Freezer using aFreon refrigerant, the Freon-based thermodynamic cycle typically has alower operating temperature limit of −86° Celsius.

It will be appreciated that the refrigeration device 106 may includeplural component parts, some of which may be installed within and/oradjacent to compartment 108. Certain embodiments employ a thermallysensitive instrument 102, typically in thermal communication with thestorage compartment 108, to measure temperature within a compartment 108of freezer 100. Accordingly, at least a portion of instrument 102 may beprovided within the compartment 108 to permit accurate measurements oftemperature within compartment 108. Other methods for measuringtemperature may be employed in accordance with certain aspects of theinvention.

Thermally sensitive instrument 102 can be electrically orelectromagnetically coupled to a controller 104, which is generallylocated outside the cooled interior of the refrigeration system 100,primarily to ensure an ambient temperature for electronics componentsthat is within operational tolerances of electronics devices. Thermallysensitive instrument 102 typically comprises a thermal sensor 102, suchas a thermocouple or thermometer and a controller 104 that can bemounted externally to the freezer 100. Certain refrigerators andfreezers are manufactured with temperature measuring sensors installedin the compartment 108 and, in some embodiments, such sensors can serveas instrument 102.

Location of the controller 104 may be selected to facilitate access topower, for optimal wireless communication and/or for easy access duringsetup and maintenance. Controller 104 may include one or moreprocessors, storage and means of communications as will be addressed inmore detail below. Placement of the controller 104 on the outside of thefreezer serves to ensure any contents inside of the compartment 108 willnot damage the sensor 102 or inhibit transmission of the readings. Insome embodiments, controller 104 may comprise a wireless transmitter.However, sensor 102 may employ hard-wired or other communication meansinstead of, or in addition to, a wireless transmitter. Controller 104can be powered by internal battery and/or from an external power sourceor supply.

In certain embodiments, controller 104 may receive temperaturemeasurements from one or more sensors 102 and may transmit accumulatedtemperature readings representing conditions within at least onecompartment 108 over a predefined time interval. It is contemplated thatsome controllers 104 may be configured to relay temperature measurementswithout processing and/or may relay temperature measurements whencontacted by another controller (not shown), gateway and/or accumulationdevice, regardless of the amount of data accumulated by the controller104.

With reference to FIG. 2, temperature measurements can be sent fromcontrollers 20, 21 via a network 24 to a processing system 28, which mayinclude one or more computers and/or servers. Controllers 20 may provideinformation, including temperature measurements, to a gateway 22, tominimize complexity of each controller 20 and/or to improvecommunications efficiency. Gateway 22 can typically receive the data andmay optionally pre-process the data into data sets which are then sentto an application server 28 for processing. In one example, gateway 22packages 10 to 20 measurements per device 20 into a data set fortransmission through network 24. Application server 28 can comprise adatabase 26 such as, for example, a schema-less database.

In certain embodiments controller 21 may communicate directly withnetwork 24 without an intervening gateway 22. Typically, a controller 21that can communicate directly with the network is configured toaccumulate and order at least some measurements. Controller 20 or 21 mayconnect to network 24 using one or more repeaters, radio signalamplifiers, a mesh network and/or other sensors 20, 21 configured toperform relay functions. Accordingly, the range of sensor 20, 21 can beextended if the distance between the sensor 20 or 21 and the gateway 22exceeds the transmission capabilities of the sensor 20 or 21. It will beappreciated that one or more sensors 20 or 21 may be connected to awired network and may communicate with gateway 22 and/or server 28 usinga LAN, WAN, Internet, Intranet, Extranet or other network. Moreover, awired controller 21 may be configured in some embodiments to relaymeasurements transmitted wirelessly from other sensors.

FIG. 3 depicts illustrative examples of profiles generated fromtemperature measurements for one type of refrigeration unit. Theseprofiles are typically generated from temperature data captured over aperiod of time, and analysis of the temperature data can be used todetermine freezer performance over the time period. Baseline profilescan be obtained as an aggregate of profiles of a plurality of similarfreezers and/or from a freezer that is functioning within ratedspecifications. In particular, temperature cycles within the compartmentcan be characterized using statistical and pattern analysis techniquesto derive a steady-state characteristic of temperature within thecompartment.

A baseline value for a population of freezers of various manufacture andmodels can be established by comparing the plotted curves of each unitto one another in order to establish a normalized average pattern. Abaseline can also be established using previously captured data obtainedfrom a similar model freezer or group of freezers known to be running atnominal and/or optimal performance levels. Baseline data can be providedby a user and/or by download from a networked repository of baselines.Baseline data can be used for comparison with a temperature profilecaptured from an individual unit and the comparison may then yieldinformation correlated to the health of the individual unit. Manyapproaches in establishing a baseline are conceivable, and some of theseapproaches may be user-defined. In certain embodiments, any appropriatecomparison metric may be used. In one example, the comparison metric maycomprise a statistical moving average.

In FIG. 3, an idealized and simplified baseline profile 300 of a freezeroperating at optimal conditions is generally sinusoidal. The sine curveoscillates about −80° Celsius and has a consistent amplitude withminimum and maximum values of −84° Celsius and −76° Celsius,respectively. In this example, the refrigeration cycle may be consideredto be active while the internal freezer temperature is greater than −80°Celsius and is disabled when the temperature is at, or below the nominaloperating temperature of −80° Celsius. Because of thermal inertia withinthe freezer, temperature continues to change after the refrigerationcycle transitions between on and off. It will be appreciated that thevolume and mobility of air within the freezer typically dictates thefrequency of oscillation of temperature. Accordingly, the sample rate oftemperature may be adjusted based on frequency of oscillation.Typically, at least two temperature readings per time period is requiredto capture frequency of oscillation, although more samples are generallyrequired to identify the form of the curve, harmonic frequency contentand step functions attributable to events, malfunction, etc.

Variations of maximum, minimum and median temperatures from nominalvalues, and/or shape of sections of the temperature characteristic canbe used to assess the efficiency of the thermodynamic cycle and toindicate potential operational deficiencies of the refrigerationequipment. Temperature measurements can be analyzed and compare thefreezer's performance to a baseline or stages during operation. Analysisof continuous temperature readings taken from individual freezers orgroups of freezers can provide data or a pattern of temperature profilesthat can be used to optimize power usage, schedule maintenance visitsand generate alarms.

Signal analysis can be performed on a temperature profile using, forexample, a statistical model. For example, a profile may indicate a peakrepresenting a maximum temperature that terminates a rise from minimumto maximum values. The peak may be calculated as a statistical maximum.The profile may also indicate a minimum temperature terminating a fallin temperature as compartmental temperature is regulated. The minimumtemperature may be calculated as a statistical minimum. In one example,the statistical maximum and minimum values may be calculated using amoving average. A statistical model can distinguish a true maximumand/or minimum temperature from other peaks and troughs in temperatureidentified within the profile. It will be appreciated that a variety ofdata filtering and analysis tools are known that can be applied toextract statistically significant characteristics of the profile. Suchstatistically significant characteristics can be used to manage freezerhealth.

The characteristics of a unit's temperature profile can be used todiagnose potential problems with refrigeration and other devices and canalso be used to identify failing components. Advantageously, data can beobtained using wireless sensors from one or more refrigeration devicesand the data can be characterized and categorized according to knowncorrelations. As discussed above, the example of FIG. 3 provides aprofile 300 representing a freezer operating at optimal conditions. FIG.3 also shows a profile 304 that is a simplified example of compressorsaturation when temperature within the freezer reaches the operationallimit of Freon at −86° Celsius. It will be appreciated that profile 304most likely represents a system in which the thermostat is set justabove −86° Celsius and that the compressor continues to operate withouteffect until temperature within the freezer stabilizes at −86° Celsiusor the temperature surrounding the thermostat reaches the set desiredtemperature. Clearly, the system represented by profile 304 is operatinginefficiently because the compressor operates without producing usefulwork.

A profile 302 with a higher frequency, more rapid refrigeration cycles,in comparison to the baseline 300, might be attributed to an incorrectlycalibrated freezer relative to its storage capacity. Observedtemperatures that fall outside a range of internally calibratedtemperature ranges may indicate one or more problems including, forexample, a Freon leak through a valve or through a deteriorating seal,lack of Freon circulation due to a clogged capillary tube, aninefficient or damaged condenser fan, a clogged filter, obstructedcondenser coils, worn compressor valves, and/or other mechanicalfailure. A greater amplitude of oscillation during a compressor cyclemay indicate a transfer of energy between the freezer and thesurroundings in the form of heat resulting in increased power usage. Arise in temperature results in more current being drawn through theunit. An irregular spike in temperature can indicate damaged insulationwithin the compressor coil. As discussed herein, deviations from anormal or ideal temperature characteristic can be correlated withdysfunctions of the cooling system 106, inadequate air circulationwithin the compartment 108 of refrigerator or freezer 100 (see FIG. 1).Correlations of dysfunction with observed temperature cycles are enabledin certain embodiments of the invention by observing, recording andanalyzing temperature variations in a plurality of refrigeration devicesover prolonged periods of time.

FIG. 4 depicts an example of a temperature characteristic 40 of anidealized freezer compartment monitored according to certain aspects ofthe invention. The characteristic 40 identifies certain inferences thatcan be drawn regarding condenser and compressor cycles. As depicted, thecharacteristic is substantially sinusoidal having a phase shiftedhalf-cycle 400 that corresponds to a period when the condenser of thefreezer is active, followed by a half-cycle 404 when the condenser isinactive. Condensers function to cool the refrigerant, such as Freon,and convert the vapor into a liquid while at a constant temperature andpressure.

The phase shift between temperature characteristic 40 and the condenserhalf-cycles 400 and 404 can arises because of lags 402 and 406 inmeasured temperature response to compressor transitions between activeand inactive, air flow within compartment 108 and for other reasons. Intypical applications, condenser half-cycles 400 and 404 may be affectedby other stages and characteristics of a refrigeration cycle, such asflash point evaporation and movement of the refrigerant through theevaporator. Transition between condenser half-cycles 400 and 404 may becorrelated with a point in time before the highest temperature observedand corresponding to the crossing of an upper temperature threshold 408.Transition between condenser half-cycle 404 and next compressor activehalf-cycle 401 may be correlated with a point in time before the lowesttemperature observed and corresponding to the crossing of a lowertemperature threshold 410.

In certain embodiments, compressor activity can be inferred from thetemperature characteristic 40. In the symmetric example of FIG. 4,temperature characteristic 40 is symmetric and phase shifts 402 and 406can be assumed to have an equal length of time and effectively ignored.Therefore, it can be inferred that the condenser is turned on for 50% ofthe time. In other instances, the ratio of active and inactive condenserperiods may be non-unitary and the resulting temperature characteristicis likely to non-sinusoidal but is likely to be periodic. Accordingly,signal analysis techniques may be employed in some embodiments toextract a fundamental frequency of the refrigeration cycle and toidentify other cycles that can be attributed to condenser activity andinactivity. In some embodiments, analysis of the temperaturecharacteristic may identify acceleration/deceleration of rate of changeof temperature within a half cycle of the temperature characteristic;these changes in acceleration and/or deceleration, and general trends inthe temperature characteristic before such changes can be used toidentify compressor on/off transitions.

Other functions of a refrigerator may be identified from the temperaturecharacteristic. For example, changes in the characteristic and/or thepresence of certain harmonic frequencies may indicate when a pump isengaged, when refrigerant vapor is compressed and/or superheated. Longterm changes in an observed temperature characteristic can be predictiveof refrigeration system failure or loss of energy efficiency. Forexample, progressive deterioration of mechanical parts can lead tochanges in the temperature characteristic (e.g. increased cyclefrequency) that are detectable, given sufficient lapsed time. The rateof change and the manner of change can indicate impending loss ofefficiency or failure based on similar changes previously observed otherrefrigeration devices.

It is also contemplated that the relationship between multiple connectedcompressors within a freezer can be identified by analysis of atemperature characteristic. In one example, the high pressure outputstage of a first compressor can be coupled to the low pressure inputstage of a second compressor. In another example, refrigeration systemsmay operate in parallel. Other refrigeration component combinations arecontemplated. The relationship between the coupled compressors can beidentified in a single temperature characteristic obtained from afreezer, while the state of health of each individual compressor in thecombination may be inferred. As discussed herein, the cooling devices ofsome commercial refrigerators and freezers are instrumented such thatdirect temperature readings from compressors, evaporators and Freonlines may be obtained and used to augment temperature readings obtainedfrom within the compartment 108. Such direct readings can be useful inisolating specific components in predictive failure analyses. Certainembodiments develop information regarding relationships between directreadings and measured compartment temperatures; such relationships maybe used to identify problems with heat transfer elements and airflowwith a compartment 108.

The attribution of potential problems to specific refrigeration unitsand/or component can be achieved in certain embodiments of theinvention. In particular, the use of indirect temperature and/orelectrical current measurements can determine the financial cost andbenefit associated with each refrigeration unit. Measurement ofelectrical current can supplement cost/benefit analysis. For example,condenser activity may be accurately characterized for a plurality offreezers and such characterization may be used to estimate power usage,based on rated current usage of the condensers. However, amalfunctioning or laboring condenser may consume considerably more powerthan a nominally operating condenser. Therefore, in certain embodiments,the monitoring of a population of refrigeration/freezer devices caninclude measurement or estimation of electrical current usage and theeffects of dysfunctional refrigeration components on power consumption.Information developed from such monitoring can be used to correlateelectrical current readings to power consumption of condensers. Forexample, information from monitoring can be used to determine the amountof electrical current drawn by a condenser and the temperaturecharacteristic for the refrigerator can be used to determine the amountof time that the condenser is active.

Electrical current usage of the condensers can be characterized for eachindividual freezer, for makes and models of freezer and can electricalcurrent can be measured on a continuous or periodic basis. In certainembodiments, current measurements can be obtained for a freezer orrefrigerator that is operating at designed efficiencies. Thesemeasurements can be correlated with temperature measurements for therefrigerator and freezer and can serve as a baseline for monitoringenergy efficiency and for predicting failure.

Electrical current usage may be used to calculate power consumption bythe refrigeration unit. The active power P required by a refrigerationunit operated at V volts and drawing I amps, is calculated as P=IV.Power used is then calculated as PT_(ON) Watt Hours (typically stated askilowatt hours), where T_(ON) is the fraction of each temperature cyclewhen the compressor is active and drawing current. It will beappreciated that actual power usage may be obtained by scaling activepower P with known power factors of the compressor or compressor type.Thus, calculation of power consumption by a freezer requires knowledgeof current used by the refrigeration unit.

In certain embodiments, current load for an individual freezer may bedetermined or inferred, given that the power cycling properties of thefreezer are predictable and/or determinable. In certain embodiments,electrical current measurements can be obtained for each refrigerator orfreezer. In certain embodiments, current is measured at a powerdistribution panel, or on a power line that supplies current to multiplerefrigerators and/or freezers. Baseline measurements of electricalcurrent drawn through a circuit supplying two or more refrigerationunits or freezers can be used to determine the load of eachrefrigeration unit or freezer. Given sufficient time and data points, aperiodic measurement of current in a circuit that feeds plural freezerscan provide sufficient information to discern the contributions ofcurrent use by each of the freezers. Typically, variations in currentmeasured at the power source can be correlated with temperaturecharacteristics measured simultaneously at each of the freezers, therebyattributing current usage by refrigeration unit or freezer.

Temperature and current correlations may be determined using a varietyof techniques. In a simple example, when a temperature characteristicshows that a selected freezer is in a warming phase, it can be assumedthat the selected freezer is drawing no current. When the selectedfreezer begins a cooling phase, any increase in measured electricalcurrent may attributed to the selected freezer, if no other freezer hastransitioned from “on to off” or from “off to on.” Given sufficient datapoints, the individual contribution of each freezer can be calculatedbased on identified combinations of “on and off” freezers. It isfrequently more convention to perform a frequency domain analysis ofmeasured electrical current flow to find correlations with temperaturecycles of refrigerators or freezers that receive the electrical current.In a simple example, if four freezers are provided electrical currentfrom the same power outlet, and the compressors of the freezers operateat different frequencies, it would be sufficient to use a notch filtertuned to the frequency of a selected freezer to measure the amplitude ofcurrent attributable to the selected freezer. However, current andtemperature data are typically analyzed using well-known signal analysistechniques.

Attribution of current consumption by individual freezers may includethe use of various algorithms that identify variations in current usageover a refrigeration cycle and can provide an average electrical currentflow and percentage “on” time for each compressor. Having determinedelectrical current usage and “on-time” for each refrigeration device, auser can determine power usage for each freezer over time, in comparisonto other systems, and in comparison to benchmarks and/or nominaloperating specifications. Thus, a single electrical current measurementdevice can provide insight into the efficiency of multiple systems.Indirect estimation of electrical current load drawn through anindividual unit can also allow for a measurement of efficiency based onenergy consumption when compared with a healthy unit.

In certain embodiments, methods for calculating power usage includemeasuring electrical current in a power line that supplies a pluralityof freezers. Electrical current measurements are typically sampled at asufficient rate to enable correlation of variations in electricalcurrent flow with the characteristics of the individual freezers. Aprocessor or controller can be configured to identify when eachcompressor is active, typically by analyzing the temperaturecharacteristic for the freezer. At various sample points in time, a listof active compressors can be associated with a current measurement inthe common power supply. With sufficient samples, the contribution ofelectrical current by each compressor can be calculated. Thiscontribution represents electrical current consumed by the compressorand can be used to calculate the power consumption of the freezer basedon the ratio of compressor active/inactive period. Accordingly, theefficiency of each freezer can be dynamically monitored.

In certain embodiments, a temperature sensor can recognize eventsrelating to changes in temperature and respond by increasing samplerate. An application server may be configured to treat such increasedsample rate as an alert for the corresponding freezer. It iscontemplated that an alert may be triggered by any of a plurality ofevents, including detection of compartment temperature rising above oneor more thresholds, temperature remaining above a maximum threshold fora predetermined amount of time, changes in rate of change of temperatureand step changes in temperature. Similarly, alerts may be generatedbased on abnormal or sudden increase in current consumption. An alertrelated to temperature rising above a threshold can often be attributedto the door being opened. If the temperature readings remain at orexceed the maximum temperature, the freezer door may be been left open,and/or complete compressor failure may have occurred. Events may alsoinclude temperature range shifts from statistical norms for the freezer,often attributable to a failing or laboring compressor, incorrectcalibration and/or changes in environmental conditions. For example, acompartment of a freezer may be overloaded given its storage capacity,and therefore unable to maintain a steady temperature. Alerts aretypically sent to a user by Email, text message automated call,notification on a Web page and/or by any other suitable means.

Environmental changes may affect temperature readings and can includethe specific placement of a freezer within a room adjacent to anunaccounted for heat sink. Freezers located near or by a window maydisplay increases in temperature that correlate to a temperatureincrease due to time of day and/or seasonal weather. The temperature ofthe room or structure in which the freezer is housed may increase due toimproperly functioning or set environmental controls. An increase intemperature readings can also correlate to an increase in current orpower usage, as the compressor does more work to maintain compartmenttemperature. In certain embodiments, a collective efficiency metric canbe calculated as power usage per area occupied by freezers. One suchmetric can be calculated as kWh/sq. ft. and the metric may be used toassess relative efficiency between different makes and models offreezers. The metric may also be used to set thresholds for performancesuch that a decrease in performance may trigger an alert, generate aservice request, etc.

In certain embodiments, portions of data collected by temperature and/orelectrical current sensors may be eliminated from consideration whencharacterizing operation of freezers, when identifying energyinefficiencies and for the purposes of predicting failure. It has beenobserved that most events, discontinuities and distortions in observedtemperature characteristics can be attributed to human activity. Humanactivity that affects the temperature characteristic includes opening ofthe freezer or refrigerator, moving of the freezer or refrigerator,vibrations caused by human activity affecting airflow, variations inpower supply due to use of electrical equipment and so on. Accordingly,analysis of data may be restricted to certain times of day when humansare not present. For example, freezers in commercial establishments maybe monitored during early morning hours.

In certain embodiments, elements of the cooling system may beinstrumented. For example, some commercially available freezers areshipped with temperature sensors installed in or around compressors,evaporators and conduits that carry Freon or other refrigerants.Typically, the temperature sensors are wired through a harness to one ormore connectors for diagnostic and maintenance. In some embodiments,signals from these additional temperature sensors can be monitored bycontrollers provided according to certain aspects of the invention. Theadditional data derived from these signals can be analyzed to obtainadditional baseline characteristics and to permit more preciseidentification of inefficiencies or dysfunction and to predict systemfailures. For example, temperature readings associated with variousaspects of the cooling system can be used to characterize nominal andoptimal cooling cycles.

In certain embodiments, a vibration sensor, such as a low frequencyaccelerometer, can detect vibration of a compressor. Compressorvibration normally occurs as a compressor is cycling on and/or off. Thesensor can respond to changes in vibration patterns and/or can comparemeasured vibration to previously recorded or observed operating norms.Response may include an increased sampling rate which typically isinterpreted by an application server as an alert. An alert may beprocessed when vibration occurs at an abnormal time interval. Forexample, a longer than normal vibration, or vibration at an unexpectedtime within the compressor cycle. Extended periods of observed vibrationcan provide a baseline for normal compressor function. In at least someembodiments, the vibration sensor may detect unusual vibrations that maybe attributable to external events such as earthquakes or relocation ofa freezer.

In certain embodiments, performance of freezers, compressors and alertscan be presented to users at a console or monitor. Users may access amonitoring system using an Internet application or browser, through asmartphone application, using a computer or tablet, or by any suitablesystem that supports user interactions with a networked console orcontrol application. By means of a graphical user interface accessed viaany Internet browser, user-specific data can be accessed from anapplication server 28 using a distinct login ID/password. Online macrosmay score the performance of each freezer. In one embodiment, a lettergrade of A, B, C or F can be assigned to compare the unit with abaseline grade or peer performance. For example, freezers assigned agrade of C or F can be marked and shut down for preventive maintenance,while freezers rated with an A or a B grade may be allowed to remain inoperation with no planned preventative maintenance.

If preventive maintenance is performed, a user, such as the servicetechnician, can manually enter data into the online system. The user cantrack potential problems, allowing for intervention before failureoccurs. Certain embodiments of the invention may also allow the user toselect a logic function to predict future performance. This function canallow the user to input scenarios that project total cost of ownershipfor each system. The function can also calculate potential savings ofeconomy, if, for example, F-grade freezers were to run at B-gradeefficiency levels. By identifying systems with a low grade, totalnon-operational time for all systems, cost for repair, and risk to thematerials being stored can be reduced.

Certain embodiments of the invention can map 2D images, such as a floorplan, of a structure to create a 3D representation of a freezer andother objects housed with varying elevation or user-defined region ofthe structure. A user can manipulate the 2D image(s), which can bereflected in pseudo-real time in the 3D structure, without the use of aseparate animation software. The freezer(s) can be classified within adatabase to control for use and context, and a hierarchical relationshipmay be created to simplify management of the freezer(s) and structures.The freezer(s) may be displayed in a single view, including all units onall floors in a structure or multiple structures, or in discrete viewsby regions. Floors can also be hidden from view in order to simplifymulti-floor structures. Certain embodiments can provide further detailsof a selected 3D view of a floor to be shown in a 2D map, in order tomanage information and placement of objects. Other embodiments of theinvention can enable the user to manipulate the 3D view, while theobjects maintain position relative to an established coordinate system.

Certain embodiments of the invention can also provide a means formonitoring and tracking the location of objects, such as a freezer ormultiple freezers R1-R10 within different regions of a structure or indifferent structures, as shown in FIG. 5. Each freezer can be assigned adistinct icon, relevant identifying information, and strategicallyincorporated in a virtual layer. A distinct icon can indicate an alarmstatus by its changed color or an action, such as a spinning orrevolving motion. For example, a freezer with an alarm status may berepresented by a red icon and/or a spinning icon. In certainembodiments, animation of an icon may correlate to a specific event ortype of alarm. For example, a rapidly spinning icon can represent afreezer with an observed increase in energy consumption. A red icon mayrepresent a freezer that has been improperly (re)located within thestructure. A blinking icon can represent a freezer while it is beingmoved.

For each freezer 500 (generally designated Rn), a device 502, such as amagnetometer, can be electrically connected to the temperaturemonitoring device and placed near the freezer door 504. Readings of afreezer's and/or freezer door's relative position can be transmitted tothe application server 28 by an integrated transceiver or RFtransmitter, which may be powered through the use of a currenttransducer, for example, an inductively coupled device, to utilize powerfrom a voltage supply source to a compressor. The current transducer mayalso be used to a charge a battery, charge-pump circuit or power anydevice, display or attached integrated circuit. The information from themagnetometer can be used to determine the orientation of the freezerrelative to a wall or structure and monitor when a freezer is moved fromone location to another. Readings from the magnetometer can alsoindicate when the door is open and can account for irregularities intemperature data. Energy is added to the conditioned area when the dooris opened and is not an indication of compressor performance to be usedin the health analysis of the freezer. In addition to a temperaturesensor, integrated transceiver, and current transducer, a comprehensivemonitoring unit may also include additional attached digital inputdevices, such as an attached humidity sensor.

System Description

Turning now to FIG. 6, certain embodiments of the invention employ aprocessing system that includes at least one computing system 60deployed to perform certain of the steps described above. Computingsystems may be a commercially available system that executescommercially available operating systems such as Microsoft Windows®,UNIX or a variant thereof, Linux, a real time operating system and or aproprietary operating system. The architecture of the computing systemmay be adapted, configured and/or designed for integration of somecomponents in the processing system, for embedding in one or more of animage capture system, a manufacturing/machining system, a graphicsprocessing workstation and/or a distributed network of devices. Atypical computing system 60 may comprise a bus 602 and/or othermechanisms for communicating between processors, whether thoseprocessors are integral to the computing system 60 (e.g. 604, 605) orlocated in different, perhaps physically separated computing systems 60.Device drivers 603 may provide output signals used to control internaland external components.

Computing system 60 also typically comprises memory 606 that may includeone or more of random access memory (“RAM”), static memory, cache, flashmemory and any other suitable type of storage device that can be coupledto bus 602. Memory 606 can be used for storing instructions and datathat can cause one or more of processors 604 and 605 to perform adesired process. Main memory 606 may be used for storing transientand/or temporary data such as variables and intermediate informationgenerated and/or used during execution of the instructions by processor604 or 605. Computing system 60 also typically comprises non-volatilestorage such as read only memory (“ROM”) 608, flash memory, memory cardsor the like; non-volatile storage may be connected to the bus 602, butmay equally be connected using a high-speed universal serial bus (USB),Firewire or other such bus that is coupled to bus 602. Non-volatilestorage can be used for storing configuration, and other information,including instructions executed by processors 604 and/or 605.Non-volatile storage may also include mass storage device 610, such as amagnetic disk, optical disk, flash disk that may be directly orindirectly coupled to bus 602 and used for storing instructions to beexecuted by processors 604 and/or 605, as well as other information.

Computing system 60 may provide an output for a display system 612, suchas an LCD flat panel display, including touch panel displays,electroluminescent display, plasma display, cathode ray tube or otherdisplay device that can be configured and adapted to receive and displayinformation to a user of computing system 60. Typically, device drivers603 can include a display driver, graphics adapter and/or other modulesthat maintain a digital representation of a display and convert thedigital representation to a signal for driving a display system 612.Display system 612 may also include logic and software to generate adisplay from a signal provided by system 60. In that regard, display 612may be provided as a remote terminal or in a session on a differentcomputing system 60. For example, a temperature or other sensor may becontrolled using a scaled down system that can be accessed by a mobiledevice or network system that can process image and other data undercontrol of a controller, an operator, an administrator or other user. Aninput device 614 may be connected in some instances. Input device 614may be provided locally or through a remote system and typicallyprovides for alphanumeric input as well as cursor control 616 input,such as a mouse, a trackball, etc. It will be appreciated that input andoutput can be provided to a wireless device such as a PDA, a tabletcomputer or other system suitable equipped to display the images andprovide user input.

According to one embodiment of the invention, data analysis may beperformed by a remote computing system 60 and/or by a sensor controllerand/or gateway device each having a processor 604 and/or 605. Processor604 and/or 605 executes one or more sequences of instructions. Forexample, such instructions may be stored in main memory 606, having beenreceived from a computer-readable medium such as storage device 610.Execution of the sequences of instructions contained in main memory 606causes processor 604 to perform process steps according to certainaspects of the invention. In certain embodiments, functionality may beprovided by embedded computing systems that perform specific functionswherein the embedded systems employ a customized combination of hardwareand software to perform a set of predefined tasks. For example,controllers, sensors and gateways may communicate with a network using apredefined protocol, such as Zigbee, TCP/IP, etc. Thus, embodiments ofthe invention are not limited to any specific combination of hardwarecircuitry and software.

The term “computer-readable medium” is used to define any medium thatcan store and provide instructions and other data to processor 604and/or 605, particularly where the instructions are to be executed byprocessor 604 and/or 605 and/or other peripheral of the processingsystem. Such medium can include non-volatile storage, volatile storageand transmission media. Non-volatile storage may be embodied on mediasuch as optical or magnetic disks, including DVD, CD-ROM and BluRay.Storage may be provided locally and in physical proximity to processors604 and 605 or remotely, typically by use of network connection.Non-volatile storage may be removable from computing system 60, as inthe example of BluRay, DVD or CD storage or memory cards or sticks thatcan be easily connected or disconnected from a computer using a standardinterface, including USB, etc. Thus, computer-readable media can includefloppy disks, flexible disks, hard disks, magnetic tape, any othermagnetic medium, CD-ROMs, DVDs, BluRay, any other optical medium, punchcards, paper tape, any other physical medium with patterns of holes,RAM, PROM, EPROM, FLASH/EEPROM, any other memory chip or cartridge, orany other medium from which a computer can read.

Transmission media can be used to connect elements of the processingsystem and/or components of computing system 60. Such media can includetwisted pair wiring, coaxial cables, copper wire and fiber optics.Transmission media can also include wireless media such as radio,acoustic and light waves. In particular radio frequency (RF), fiberoptic and infrared (IR) data communications may be used.

Various forms of computer readable media may participate in providinginstructions and data for execution by processor 604 and/or 605. Forexample, the instructions may initially be retrieved from a magneticdisk of a remote computer and transmitted over a network or modem tocomputing system 60. The instructions may optionally be stored in adifferent storage or a different part of storage prior to or duringexecution.

Computing system 60 may include a communication interface 618 thatprovides two-way data communication over a network (didn't see thislabeled) that can include a local network 622, a wide area network orsome combination of the two. For example, an integrated services digitalnetwork (ISDN) may be used in combination with a local area network(LAN). In another example, a LAN may include a wireless link.Communication interface 618 typically provides data communicationthrough one or more networks to other data devices. For example,communication interface 618 may provide a connection through localnetwork 622 to a host computer 624 or to a wide area network such as theInternet 628. Local network 622 and Internet 628 may both useelectrical, electromagnetic or optical signals that carry digital datastreams.

Computing system 60 can use one or more networks to send messages anddata, including program code and other information. In the Internetexample, a server 630 might transmit a requested code for an applicationprogram through Internet 628 and may receive in response a downloadedapplication that provides for the anatomical delineation described inthe examples above. The received code may be executed by processor 604and/or 605.

Additional Descriptions of Certain Aspects of the Invention

The foregoing descriptions of the invention are intended to beillustrative and not limiting. For example, those skilled in the artwill appreciate that the invention can be practiced with variouscombinations of the functionalities and capabilities described above,and can include fewer or additional components than described above.Certain additional aspects and features of the invention are further setforth below, and can be obtained using the functionalities andcomponents described in more detail above, as will be appreciated bythose skilled in the art after being taught by the present disclosure.

As discussed with reference to FIG. 1, thermally sensitive instruments102 can be deployed in a plurality of refrigerators and freezers 100 tomonitor compartment temperatures and to deduce characteristics ofperformance and efficiency for individual devices 100 and to predictfailure or deterioration in performance. The characteristics aretypically derived from information gathered over long periods of time,the information including temperature measurements gathered during thattime. Other components of the information can optionally includemeasurements of electrical current for one or more devices 100, ambienttemperatures of rooms that house devices 100, compressor/evaporatortemperature measurements and other information obtained from othersensors mounted in device 100, detected exceptions such as freezer 100door openings and so on. Observational and maintenance information canbe provided by technicians dispatched to service machines, suchinformation including readouts from control systems of device 100,diagnostic equipment, etc.

Temperature, electrical current and other measurements are typicallyobtained as samples, taken at a frequency calculated to capturefundamental periods of temperature change. Information obtained fromeach of the plurality of devices can be used to characterize theperformance of the system 100 and may be stored as a set of rawmeasurements, as averaged characteristics of temperature, electricalcurrent and power consumption. In some embodiments, the measurements maybe subjected to a frequency domain analysis to obtain a set ofparameters that describes the observed temperature and electricalcurrent curves. Accordingly, the characteristics of a specificrefrigerator may be stated as parameters that include a set ofamplitudes of a fundamental frequency and its harmonics, one or morephase shifts and one or more transforms, such as a Fourier transform, aLaplace transform, or any other suitable transform. Such frequencydomain representation may be particularly useful when seeking patternsin the characteristics of a device 100 and/or when matching temperatureand electrical current measurements, especially where there are fewercurrent meters than freezers 100. Statistical analysis and other formsof data processing may be used for characterizing performance andidentifying trends or patterns. In certain embodiments, digital signalprocessors may be used in the probe and/or monitoring system to generatefrequency domain representations of temperature characteristics and/orcurrent signals measured in a power line.

Baseline characteristics are typically developed for each brand andmodel of freezer 100. In certain embodiments, a baseline may bedeveloped from one or more devices 100 that are known to be performingnominally. However, baseline performance can be obtained without using aknown optimally performing device 100. Over time, and with a sufficientpopulation of devices, a baseline may be extracted by identifying levelsof performance (e.g. levels A, B, C E and F discussed herein) within thepopulation of devices. Levels of performance may be assigned accordingto manufacturer specifications, user requirements, standards set bypower companies or utility commissions, etc. Levels of performance maybe used to determine eligibility for energy conservation rebates and thelike and/or to identify candidates for replacement.

Baseline characteristics may be modified over time to reflect actualperformance measurements that better reflect typical performance of adevice 100 while in use. In use, performance of device 100 may beaffected by the volume of materials stored in compartment 108, by thearrangement of stored materials and by the shape of packaging of storedmaterials. Performance of device 100 may also be affected by dooropenings, vibrations, changes in room temperature, and so on. As notedherein, it is often desirable to measure performance of device 100 attimes when human interactions are minimized, for example, early morningor late evening. However, measurements taken at other times may beuseful determining other performance characteristics, such as the timeand energy required to restore operating temperatures after a disruptionor discontinuity, such as an opened door. These other performancecharacteristics may useful in determining which type of device 100should be used for long-term storage and which device 100 should be usedwhen subject to frequent access.

It is to be expected that the performance characteristics of arefrigerator or freezer change over time, although such changes may beso gradual as to escape detection in conventional systems. In certainembodiments of the present invention, more recent characteristics,including temperature and electrical current cycles, may be comparedwith previously obtained baseline characteristics for a device 100.Changes detected over prolonged periods of time can be correlated withknown patterns of change that are predictive of component or systemfailure, or predictive of performance degradation. In some instances,changes can simply indicate a need for maintenance. For example, ashortening of the period temperature cycle may indicate any of a numberof conditions that cause the compressor to be active more frequently.However, rate of change of the period, step changes in the rate ofchange of the period, consistency or rate of change of the rate ofchange in period and changes in duty cycle (percentage of timecompressor is turned on in a cycle) can provide additional data that maybe used to diagnose the condition of the cooling system 100 and predictfailure or loss of efficiency.

As discussed herein, performance characteristics are typicallymaintained for a variety of different types of refrigerators andfreezers 100. Information derived from temperature and cooling cyclescan be used to evaluate performance of different types of devices 100.For example, a metric can be developed that rates energy efficiency fordifferent makes and models of devices used for refrigeration orfreezing. In one example, energy efficiency may be rated as the cubicfeet that can be maintained at a specified temperature or temperaturerange for each kilowatt-hour of energy expended. This metric permitsevaluation of devices that have different compartment volumes, differentcompartment geometries, different shelf configurations, differentcooling capacities, etc. Performance characteristics gathered in situand real time may be used to evaluate performance of previously unseendevices 100 and to rate such performance against other similar ordissimilar devices. Such evaluations and ratings may be used torecommend to operators whether the device 100 should be replaced and maybe used by utilities to determine eligibility for rebates.

Certain embodiments of the invention provide systems and methods formonitoring the operational health of a refrigeration system. Certainembodiments comprise a sensor operable to measure temperature within acompartment of the refrigeration system. Certain embodiments comprise acontrol processor in communication with the sensor and configured toreceive a series of periodic temperature measurements from the sensor.In certain embodiments, the control processor is operable to communicatea sequence of temperature samples to a monitoring system thatcharacterizes one or more operational aspects of the refrigerationsystem based on the sequence of temperature samples. In certainembodiments, each temperature sample comprises at least one of theseries of periodic temperature measurements and information indicativeof a corresponding time of measurement. In certain embodiments, themonitoring system is configured to predict operational dysfunctions ofthe refrigeration system based on an analysis of the one or morecharacterized operational aspects.

In certain embodiments, the characterized operational aspects comprise atemperature cycle measured within the compartment of the refrigerationsystem. In certain embodiments, the analysis of the characterizedoperational aspects includes a comparison of the temperature cycle withone or more baseline temperature cycles previously obtained from therefrigeration system. In certain embodiments, the analysis of thecharacterized operational aspects includes a comparison of thetemperature cycle with one or more baseline temperature cycles obtainedfrom an optimally performing refrigeration system. In certainembodiments, the analysis of the temperature cycles includes astatistical analysis of the temperature cycle. In certain embodiments,the analysis of the temperature cycles includes a frequency-domainanalysis of the temperature cycle. In certain embodiments, the analysisof the temperature cycles includes a pattern analysis of the temperaturecycle.

In certain embodiments, the characterized operational aspects comprise atemperature cycle and a cycle of estimated electrical current consumedby the refrigeration system. In certain embodiments, the analysis of thecharacterized operational aspects includes estimating energy efficiencyof the refrigeration system based on the estimated electrical currentconsumed by the refrigeration system. In certain embodiments, thecurrent usage is calculated by cross-correlating a signal representativeof estimated operating current of the refrigeration system with a signalrepresentative of temperature measured within the compartment of therefrigeration system. Certain embodiments comprise a current transducerconfigured to measure current flow in an electrical circuit providingpower to the refrigeration system. In certain embodiments, thecharacterized operational aspects comprise a temperature cycle and acycle representing electrical current consumed by the refrigerationsystem. In certain embodiments, the analysis of the characterizedoperational aspects includes calculating energy efficiency of therefrigeration system based on the electrical current consumed by therefrigeration system. In certain embodiments, the electrical circuitprovides power to a plurality of refrigeration systems. In certainembodiments, the monitor attributes a portion of the current flow to aselected refrigeration system based on an analysis of temperature cyclescorresponding to the selected refrigeration system.

In certain embodiments, the monitor generates alerts in response to theidentified dysfunctions. In certain embodiments, the identifieddysfunctions including one or more of a temperature transition beyondnominal operating range, power usage beyond nominal operating ranges anda predicted failure of the refrigeration system. In certain embodiments,the characterized operational aspects comprise a temperature signalrepresentative of the temperature within the compartment and a currentsignal representative of estimated electrical current consumed by therefrigeration system. In certain embodiments, the analysis of thecharacterized operational aspects includes an estimate of energyefficiency of the refrigeration system based on the estimated electricalcurrent signal. In certain embodiments, the electrical current usage iscalculated by cross-correlating the current signal with the temperaturesignal.

Certain embodiments comprise a current transducer configured to measurecurrent flow in an electrical circuit providing power to therefrigeration system. In certain embodiments, the characterizedoperational aspects comprise a temperature signal and a signalrepresenting electrical current consumed by the refrigeration system. Incertain embodiments, the analysis of the characterized operationalaspects includes calculating energy efficiency of the refrigerationsystem based on the electrical current signal. In certain embodiments,the electrical circuit provides power to a plurality of refrigerationsystems, and wherein the monitor attributes a portion of the currentflow to a selected refrigeration system based on a correlation of thetemperature cycle with the current signal. In certain embodiments, themonitor generates alerts in response to the identified dysfunctions. Incertain embodiments, the identified dysfunctions include one or more ofa temperature transition beyond nominal operating range, power usagebeyond nominal operating ranges and a predicted failure of therefrigeration system.

Certain embodiments of the invention provide methods for monitoringoperational efficiency of a refrigeration system. Certain embodimentscomprise generating a characteristic representing a time sequence oftemperatures measured within a compartment of a refrigeration system.Certain embodiments comprise identifying differences between thecharacteristic and one or more baseline characteristics. In certainembodiments, the one or more baseline characteristics include at leastone characteristic obtained from a nominally operating refrigerationsystem. Certain embodiments comprise determining one or moredysfunctions of a thermodynamic cycle based on the differences. Incertain embodiments, the one or more dysfunctions includes a loss ofenergy efficiency, measured with respect to a baseline energy efficiencyassociated with the one or more baseline characteristics.

In certain embodiments, the one or more baselines include a previouslyobtained characteristic representing a time sequence of temperaturesmeasured within a compartment of a refrigeration system. In certainembodiments, energy efficiency is measured as volume cooled for eachunit of energy expended by the refrigeration system. In certainembodiments, the one or more dysfunctions include a predicteddysfunction, and further comprising identifying a corrective action toavert the predicted dysfunction. Certain embodiments comprise measuringelectrical current in a power line that supplies the refrigerationsystem. In certain embodiments, measuring the electrical current in thepower line includes determining the contribution of electrical currentin the power line attributable to electrical current drawn by therefrigeration system. In certain embodiments, determining thecontribution of electrical current attributable to the refrigerationsystem includes correlating changes in temperature of a storagecompartment of the refrigeration system with variations of currentmeasured in the power line.

Certain embodiments of the invention provide systems and methods formonitoring operational efficiency of a refrigeration system. Certainembodiments comprise a temperature sensor operable to measuretemperature within a refrigerated compartment of the refrigerationsystem. Certain embodiments comprise a remote probe that samplestemperature measurements provided at a configurable rate by thetemperature sensor. Certain embodiments comprise a processor thatgenerates a characteristic based on the sampled temperaturemeasurements. In certain embodiments, the characteristic representsvariations of temperature with time. In certain embodiments, thecharacteristic has a period, a maximum temperature and a minimumtemperature. In certain embodiments, the processor is configured toidentify operational inefficiencies of the refrigeration by comparingelements of the characteristic to elements of a plurality of baselinecharacteristics derived from one or more similar refrigeration systems.

In certain embodiments, the processor predicts failure of a component ofthe refrigeration system by identifying one or more differences betweenthe elements of the characteristic and the elements of the plurality ofbaseline characteristics. Certain embodiments comprise a currenttransducer configured to measure current flow in an electrical circuitproviding power to the refrigeration system. In certain embodiments, theprocessor generates a second characteristic representing electricalcurrent consumed by the refrigeration system. In certain embodiments,the processor identifies a decline in energy efficiency of therefrigeration system over time. In certain embodiments, energyefficiency is measured as volume cooled for each unit of energy expendedby the refrigeration system. In certain embodiments, the processoridentifies certain operational inefficiencies of the refrigeration bycorrelating elements of the characteristic with elements of a pluralityof baseline characteristics derived from one or more similarrefrigeration systems.

Certain embodiments of the invention provide systems and methods formonitoring the state of health of a refrigeration unit, such as afreezer, and inferring compressor performance by analysis of indirecttemperature and current readings. A comprehensive monitoring unit may becomprised of a temperature sensor, accelerometer, circuitry, ammeter,magnetometer, integrated transceiver, current transducer, and additionalattached digital input devices. Readings from a monitoring unit can betransmitted to an application server. In some of these embodiments, anapplication server may use a statistical model to perform signalanalysis on temperature and current readings.

Certain embodiments of the invention provide systems and methods ofmonitoring operational efficiency of a refrigeration system. Some ofthese embodiments comprise obtaining a characteristic representing atime sequence of temperatures measured within a compartment of arefrigeration system. Some of these embodiments comprise identifyingdifferences between the characteristic and one or more baselinecharacteristics. In some of these embodiments, the baselinecharacteristics include at least one characteristic obtained from anominally operating refrigeration system. Some of these embodimentscomprise determining one or more dysfunctions of a thermodynamic cyclebased on the differences. Some of these embodiments comprise identifyinga corrective action to optimize the operational efficiency of therefrigeration system.

Certain embodiments of the invention provide systems and methods formonitoring the operational health of a refrigeration unit. Some of theseembodiments comprise a sensor configured to measure temperature within acompartment of the refrigeration unit. Some of these embodimentscomprise a control processor in communication with the sensor andconfigured to receive periodic temperature measurements from the sensor.Some of these embodiments comprise data storage that maintains a historyof temperatures comprising at least one temperature measurement obtainedfrom the sensor. In some of these embodiments, the data storage furthermaintains information that identifies a time of measurement for each ofthe temperature measurements. In some of these embodiments, the controlprocessor transmits the history of temperatures to a monitor that isconfigured to identify dysfunctions of the refrigeration unit based onanalysis of a temperature cycle within the refrigeration unit.

In some of these embodiments, the analysis of the temperature cyclesincludes a comparison of the temperature cycle with one or more baselinetemperature cycles obtained from a nominally performing refrigerationunit. In some of these embodiments, the analysis of the temperaturecycles includes a comparison of the temperature cycle with one or morebaseline temperature cycles obtained from an optimally performingrefrigeration unit. Comparisons may be used to identify underlyingpatterns or cycles and other cycles or asymmetries that can beindicative of problems, inefficiencies, component malfunction or otherdysfunctions that cause or lead to inefficiency and/or system failure.In some of these embodiments, the analysis of the temperature cyclesincludes a statistical analysis of the temperature cycle. For example,statistical analysis may be used to filter raw data to identify andexclude anomalous measurements and/or discontinuities, such as elevatedtemperature and recovery cycles associated with a door opening event. Insome of these embodiments, the analysis of the temperature cyclesincludes a frequency analysis of the temperature cycle. Frequencyanalysis may be used to calculate a fundamental frequency of thetemperature cycle that can be used to match an electrical currentcontribution to the refrigeration system. Frequency analysis may be usedto obtain a transform that is used to characterize the cooling cycle ofthe refrigeration system. In some of these embodiments, the analysis ofthe temperature cycles includes a pattern analysis of the temperaturecycle.

In some of these embodiments, the monitor estimates power usage of therefrigeration unit based on characteristics of the temperature cycle andcurrent usage of the refrigeration unit. In some of these embodiments,the characteristics of the temperature cycle identify when therefrigeration unit is actively cooling. In some of these embodiments,the current usage is calculated based on estimated operating current ofthe refrigeration unit when the refrigeration unit is active.

Some of these embodiments comprise a current transducer configured tomeasure current flow in an electrical circuit providing power to therefrigeration unit. In some of these embodiments, the monitor calculatespower usage of the refrigeration unit based on characteristics of thetemperature cycle and the measured current flow. In some of theseembodiments, the electrical circuit provides power to a plurality ofrefrigeration units. In some of these embodiments, the monitorattributes a portion of the current flow to one or more selectedrefrigeration units based on an analysis of characteristics oftemperature cycles of the selected refrigeration units.

Some of these embodiments comprise a transducer and/or an accelerometerconfigured to identify motion, direction and orientation of therefrigeration unit. In some of these embodiments, the accelerometerdetects vibration attributable to start up and shut down of therefrigeration unit. In some of these embodiments, a magnetometerindicates the orientation of a freezer relative to a wall or structure.In some of these embodiments, the monitor calculates power usage of therefrigeration unit based on the occurrence of vibration and currentusage of the refrigeration unit. In some of these embodiments, themonitor generates alerts in response to the identified dysfunctions. Insome of these embodiments, the identified dysfunctions includetemperature transitions beyond nominal operating ranges. In some ofthese embodiments, the identified dysfunctions include power usagebeyond nominal operating ranges. In some of these embodiments, thehistory of temperature is transmitted wirelessly.

Certain embodiments of the invention provide systems and methods formonitoring operational efficiency of a refrigeration system. Some ofthese embodiments comprise a temperature sensor provided within arefrigerated compartment of the refrigeration system. Some of theseembodiments comprise a remote probe that records temperaturemeasurements from the temperature sensor at a configurable rate. Some ofthese embodiments comprise a processor that extracts a characteristicfrom the temperature measurements. In some of these embodiments, thecharacteristic represents variations of temperature with time. In someof these embodiments, the characteristic having a period, a maximumtemperature and a minimum temperature. In some of these embodiments, theprocessor is configured to identify operational inefficiencies of therefrigeration by comparing elements of the characteristic to elements ofa plurality of baseline characteristics derived from one or more similarrefrigeration systems.

Although the present invention has been described with reference tospecific exemplary embodiments, it will be evident to one of ordinaryskill in the art that various modifications and changes may be made tothese embodiments without departing from the broader spirit and scope ofthe invention. Accordingly, the specification and drawings are to beregarded in an illustrative rather than a restrictive sense.

What is claimed is:
 1. A method of monitoring operational efficiency ofa refrigeration system, comprising: configuring a controller to collectdata from one or more sensors, wherein the controller is located outsidea cooled compartment of a monitored refrigeration system andcommunicatively coupled to the one or more sensors; receiving aplurality of measurements obtained by at least one sensor of the one ormore sensors, wherein the plurality of measurements includes periodicmeasurements of temperature, current or vibration associated withoperation of the monitored refrigeration system over a period of time;generating an operational characteristic of the monitored refrigerationsystem from the plurality of measurements; identifying a trend in theoperational characteristic of the monitored refrigeration system thatindicates a variation from a nominal operational characteristic; andpredicting failure or loss of energy efficiency of the monitoredrefrigeration system based on the trend identified in the operationalcharacteristic of the monitored refrigeration system, wherein thenominal operational characteristic includes measurements of temperature,current or vibration obtained from a nominally operating refrigerationsystem.
 2. The method of claim 1, wherein the trend includes a change induty cycle in a plurality of cooling cycles of the monitoredrefrigeration system.
 3. The method of claim 1, wherein the trendincludes a change in duty cycle in a temperature cycle of the cooledcompartment in the monitored refrigeration system.
 4. The method ofclaim 1, wherein the trend includes a change in duty cycle of a currentflowing to the monitored refrigeration system.
 5. The method of claim 4,wherein the change in duty cycle of the current flowing to the monitoredrefrigeration system relates to a ratio of active periods and inactiveperiods of a compressor in the monitored refrigeration system.
 6. Themethod of claim 1, wherein the trend includes a change in vibrationsdetected in the monitored refrigeration system.
 7. The method of claim6, wherein the vibrations comprise vibrations detected while acompressor in the monitored refrigeration system is cycling on or off.8. The method of claim 1, wherein the trend includes a change in anon/off cycle of a compressor in the monitored refrigeration system. 9.The method of claim 1, wherein the nominal operational characteristic ismodified over time to reflect performance measurements obtained from themonitored refrigeration system.
 10. The method of claim 1, wherein thenominal operational characteristic characterizes performance associatedwith one or more similar refrigeration systems.
 11. The method of claim1, further comprising: scoring performance of the monitoredrefrigeration system based on differences between the operationalcharacteristic of the monitored refrigeration system and the nominaloperational characteristic.
 12. The method of claim 11, wherein scoringperformance of the monitored refrigeration system comprises: associatingthe monitored refrigeration system with a grade that categorizes theperformance of the monitored refrigeration system.
 13. The method ofclaim 11, further comprising: tracking location of the monitoredrefrigeration system with respect to a plurality of monitoredrefrigeration systems, wherein performance of each of the plurality ofmonitored refrigeration systems is scored; and associating each of theplurality of monitored refrigeration systems with a corresponding gradeand location within a structure that houses the plurality of monitoredrefrigeration systems.
 14. The method of claim 13, further comprising:marking one or more of the plurality of monitored refrigeration systemsfor maintenance or shutdown when failure or loss of energy efficiency ispredicted by operational characteristics of the one or more monitoredrefrigeration systems.
 15. An apparatus, comprising: at least oneprocessor; and a communication interface coupled to the at least oneprocessor and configured to establish a connection with a controllerthrough a communication network, wherein the at least one processor isconfigured to: configuring a controller to collect data from one or moresensors, wherein the controller is located outside a cooled compartmentof a monitored refrigeration system and communicatively coupled to theone or more sensors; receive a plurality of measurements obtained by atleast one sensor of the one or more sensors, wherein the plurality ofmeasurements includes periodic measurements of temperature, current orvibration associated with operation of the monitored refrigerationsystem over a period of time; generate an operational characteristic ofthe monitored refrigeration system from the plurality of measurements;identify a trend in the operational characteristic of the monitoredrefrigeration system that indicates a variation from a nominaloperational characteristic; and predict failure or loss of energyefficiency of the monitored refrigeration system based on the trendidentified in the operational characteristic of the monitoredrefrigeration system, wherein the nominal operational characteristicincludes measurements of temperature, current or vibration obtained froma nominally operating refrigeration system.
 16. The apparatus of claim15, wherein the trend includes a change in duty cycle in a plurality ofcooling cycles of the monitored refrigeration system or a change in dutycycle of a current flowing to the monitored refrigeration system. 17.The apparatus of claim 15, wherein the trend includes a change invibrations detected in the monitored refrigeration system, includingvibrations detected while a compressor in the monitored refrigerationsystem is cycling on or off.
 18. The apparatus of claim 15, wherein thetrend includes a change in an on/off cycle of a compressor in themonitored refrigeration system.
 19. The apparatus of claim 15, furthercomprising: scoring performance of the monitored refrigeration systembased on differences between the operational characteristic of themonitored refrigeration system and the nominal operationalcharacteristic; and associating the monitored refrigeration system witha grade that categorizes the performance of the monitored refrigerationsystem.
 20. The apparatus of claim 19, further comprising: trackinglocation of the monitored refrigeration system with respect to aplurality of monitored refrigeration systems, wherein performance ofeach of the plurality of monitored refrigeration systems is scored; andassociating each of the plurality of monitored refrigeration systemswith a corresponding grade and location within a structure that housesthe plurality of monitored refrigeration systems.